All-SiC Module for Chopper Circuit

Mega Solar PCS Incorporating All-SiC
Module “PVI1000AJ-3/1000”
In recent years, a higher degree of power
generation performance and reliability has
been demanded of photovoltaic power generation systems. Power conditioning sub-systems
(PCS) have a central role in these systems, and
are required to have a large capacity and high
efficiency, as well as reliability that enables
continuous operation even when disturbances
occur in power supply systems. In addition to
this, they must support the reduction of total
costs for the systems.
Fuji Electric has developed the mega solar
PCS “PVI1000AJ-3/1000.” The PCS employs
an All-SiC module that consists of a silicon
carbide metal-oxide-semiconductor field-effect
transistor (SiC-MOSFET), as a next-generation semiconductor device, as well as an SiC
Schottky barrier diode (SiC-SBD), enabling
the unit to achieve a maximum efficiency of
98.8 %, which is the industry’s highest level.
Furthermore, the unit achieves miniaturization with a footprint size approximately 60 %
smaller than previous products.
This product was awarded First Prize in the
FY2015 (64th) Japan Electrical Manufacturers’
Association Technical Achievement Award.
All-SiC Module for Chopper Circuit
Silicon carbide (SiC) devices have attracted a lot of attention for their potential to help
achieve a low-carbon society through their capability of significantly reducing power consumption. Fuji Electric has utilized the SiC
metal-oxide-semiconductor field-effect transistor (SiC-MOSFET) and SiC Schottky barrier
diode (SiC-SBD) devices being manufactured
on the 6-inch line at the Matsumoto Factory to
develop an All-SiC module for use in chopper
circuits.
This module has a rated capacity of 1,200 V/
100 A, and achieves miniaturization with a
footprint size approximately 55% smaller than
previous Si-IGBT modules. This module can be
used in the booster circuits of power conditioning sub-systems (PCS) for photovoltaic power
generation, and contributes to circuit miniaturization and significant reduction in power
loss. These enhancements have achieved a
20 % reduction in size for the PCS, and a conversion efficiency of 98.8 %, which is the industry’s highest level.
FUJI ELECTRIC REVIEW vol.61 no.2 2015
95
Power System Analysis Simulator for
Chubu Electric Power Co., Inc.
1G
CL1
bit
s/s
CL2
PNL
DAT
CL3
CL4
FEP
SW
SG
s/s
bit
1G
GMC
NAS
10
0M
1G
10
0M
bit
s/s
bit
s/s
bit
s/s
SW
MDL
CL1, 2, 3, 4 :
SG
:
PNL
:
:
DAT
:
FEP
:
GMC
:
NAS
:
SW
:
MDL
Client PCs
Smart grid control server
Operating & monitoring panels
Data server
Front end processor
Grand master clock
Network attached storage
Ethernet switches
Simulator models
Operation system network
IEC 61850/IEC 61588 network
Off-line setting network
Fuji Electric has provided the Power
System Analysis (PSA) Center of Chubu
Electric Power Co., Inc. with a “hybrid power
system analysis simulator” capable of simulating smart grids.
This facility is a power system analysis
simulator that utilizes real voltage and current to perform electric power system analysis,
while also enabling the simulation of a diverse
range of system configurations including distributed power sources.
It adopts an electric power communication
protocol (IEC 61850) and time synchronization
system (IEC 61588) as information communication infrastructure and can also be utilized
in the development and testing of control systems based on next-generation information
communication technology.
The simulator is expected to contribute to
the assessment of the effect of a large amount
of renewable energy on systems, as well as support the testing of smart grid technology capable of utilizing renewable energy at an optimal
level.
Exhaust Gas Cleaning System for
Ships (Cyclone Type SOx Scrubber)
In order to prevent air pollution from marine vessels, exhaust gas regulations have been
gradually reinforced based on the International
Convention (MARPOL Annex VI).
Fuji
Electric has developed an exhaust gas cleaning
system for marine vessels (SOx removal cyclone
scrubber) compliant with SOx /PM regulations
that have been reinforced in 2015. The unit
sprays sea water on the exhaust gas and reduces SOx by dissolving it in the sprayed droplets.
The main features are as follows:
(1) It achieves the industry’s smallest size (diameter of 2 m, and height of 7 m) with a volume that is more than 50 % smaller than
previous products. It can be easily installed
on both new and old ships.
(2) The cyclone system creates swirl inside the
unit to secure time for the SOx absorption
reaction.
(3) The high-diffusion spray nozzle increases
the SOx reduction rate to over 98 %, enabling the unit to meet the 2015 regulations
applicable to Emission Control Area.
(4) It achieves reduction in pressure loss and
the droplet dispersal rate by making use of
SOx dissolution model experiments and fluid simulations.
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FUJI ELECTRIC REVIEW vol.61 no.2 2015
Small- and Medium-Scale Monitoring
and Control System “MICREX-VieW XX”
XES-3000
Engineering tool
Information LAN
XDS-3000
XOS-3000
Control LAN
FL-net Ver.3
XCS-3000
(duplicated)
Network
adapter
E-SX bus
IPUⅠ
E-SX I/O
Remote I/O
IPU Ⅱ
Fuji Electric has developed and commenced sales of the Small- and Medium-Scale
Monitoring and Control System “MICREXVieW XX (Double X)” as a system standardizing control system architecture in order to
meet the requirements of industrial and social
infrastructure. This product is a system that
aggregates and integrates the technologies of
Fuji Electric at an advanced level by incorporating a variety of concepts including “superior visibility and operability,” “integration of
electric machine control and measurement control,” “high reliability,” “efficient engineering”
and “high level of inheritability.”
This product is composed of a next-generation HCI with excellent monitoring and operability, a high-speed and high-capacity controller, a highly reliable system configuration
(redundancy of components including the I/O,
controller, database, and network) and a highefficiency integrated engineering tool. By connecting a multi-function network adapter, it is
possible to make effective use of existing assets, as well as upgrade to high-reliability systems quickly and inexpensively.
Inverter for Elevators in European
Market “FRENIC-Lift LM2A”
(a) Front mounted
FUJI ELECTRIC REVIEW vol.61 no.2 2015
(b) Side mounted
In Europe, elevators are being required to
comply with reinforced safety standards and
adopt advanced control systems. In addition,
there has been increasing demand for elevators
not requiring a machine room in order to install them in existing buildings. As a result, it
is essential that the control panel be miniaturized and have a low profile so that it can be installed in the narrow space of the elevator shaft
and side of the entrance door. Fuji Electric has
developed the “FRENIC-Lift LM2A” inverter
for elevators in order to meet these needs.
The main features are as follows:
(1) Has achieved the industry’s smallest class
size through low profile enhancements that
reduce the width from 220 mm to 140 mm
compared with previous products (Built-in
7.5-kW EMC filter).
(2) Has acquired third-party certification for
European safety standards (EN81-20)
(Compliant with contactless methods for
motor output blocking).
(3) Supports major encoders in the European
market.
(4) Scheduled in FY2015 to support 2 communication functions (DCP4/CiA DSP417) for
elevator distance control.
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Medium-Frequency Isolation Type
Auxiliary Power Supply
We have developed a compact and lightweight auxiliary power supply based on a medium frequency isolation system that is suitable for subway cars and automated people
movers. Recently, lightweight enhancements
have been underway for electric rolling stock
in order to increase energy savings and control
a number of service devices, and as a result,
compact and lightweight auxiliary power supplies are in very high demand. Conventionally,
it has been mainstream to use a commercial
frequency transformer to isolate 3-phase AC,
but recently, it is becoming more common to
use a medium-frequency transformer to isolate medium-frequency voltage that has been
converted by a resonance inverter. Utilization
of medium frequency reduces magnetic flux in
the transformer core, allowing the transformer to reduce its weight to one-tenth that of the
previous product. Furthermore, we have been
aiming at reducing the switching loss of power
devices through the utilization of a resonance
inverter.
Compared to the previous system, this
auxiliary power supply has achieved a reduction by 25% in volume and 35% in mass.
Lineup Enhancement for Circuit
Protector “CP30F”
(a) “CP30FI-1P”
(b) “CP30FS-2P”
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(c) “CP30FM-3P”
A circuit protector is a circuit breaker that
is utilized in the protection of the control circuits and devices of various control panels. It
is adopted in the circuit protection components
of electronic devices. In recent years, there
has been growing market demand for control
panels and devices that are smaller, contribute
to wire savings, improve safety and are global
in scope of application. In order to meet these
needs, Fuji Electric has enhanced its lineup of
“CP30F” circuit protectors.
The main features are as follows:
(1) Integrates terminal cover functionality into
the product and achieves a reduced setting
area of 20 % compared with existing models
(2) Employs a new terminal structure and contributes to reducing labor-hours related to
connection electric wiring by 40 % compared
with existing models
(3) Adopts IP20 as the degree of protection for
the main terminal
(4) Compliant with JIS, UL, IEC and GB
standards
FUJI ELECTRIC REVIEW vol.61 no.2 2015
Fuji Electric’s Top Runner Motor
“Premium Efficiency Motor”
In recent years, there has been growing
momentum toward the reduction of global energy usage as a means of preventing global
warming. Japan has also been promoting the
expansion of equipment that adopts and applies
Top Runner Standards based on the “Act on the
Rational Use of Energy” (Energy Conservation
Act). Three-phase induction motors became
part of the top runner system in 2013, and Fuji
Electric has been supplying the market with its
“Premium Efficiency Motor” as a motor compliant with these standards.
The main features are as follows:
(1) Decreases loss by optimizing the groove dimensions, core material, etc., and achieves
Top Runner Standard efficiency at an output between 0.75 and 375 kW.
(2) Compliant with the frame number and mating dimensions specified in JIS C 4210,
while also supporting easy replacement.
(3) Improves insulation performance while
suppressing temperature rise, and also expands the range of the cast iron frame to
contribute to improved corrosion resistance
and reduced acoustic noise. Furthermore, it
adopts IP55 as the degree of protection for
the outdoor specification in compliance with
global standards.
1,200-V Withstand Voltage SiC Hybrid
Module
Fuji Electric is advancing in the development of SiC hybrid modules with a 1,200-V
withstand voltage as power devices that can
be utilized in inverters that contribute to energy conservation. The hybrid module utilizes an SiC Schottky barrier diode (SiC-SBD)
chip that was developed in collaboration with
the National Institute of Advanced Industrial
Science and Technology. The chip is being manufactured on the 6-inch line at the Matsumoto
Factory. The insulated gate bipolar transistor (IGBT) is equipped with Fuji Electric’s latest 6th generation “V Series” IGBT chip. The
package for this SiC hybrid module utilizes the
same 2-in-1 package as the Si module in order
to maintain compatibility. It reduces loss by
about 25% compared with conventional Si modules with a rated capacity of 300 A.
FUJI ELECTRIC REVIEW vol.61 no.2 2015
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2nd Generation IPM for Hybrid
Vehicles
(a) External appearance
Chip/ Electrode layer
Aluminum wire
Copper terminal
Solder
Isolation substrate
Solder
Cooler
(b) Cross-section view
There has been an increasing demand for
smaller and lighter weight intelligent power
modules (IPM) for use in the motor control of
hybrid electric vehicles (HEV) and electric vehicles (EV).
Fuji Electric has enhanced its 2nd generation aluminum direct water-cooled IPM by
improving heat dissipation for the cooler and
providing higher temperature stability for the
bonding materials, as well as by reducing the
footprint through the adoption of ultrasonic
welding. As a result, it is much smaller than
the 1 st generation model. Specifically, we have
developed the following: a cooler design technology for the aluminum direct water-cooled
structure that integrates the heat sink and water jacket; high temperature stability materials (aluminum wire, electrode layer and solder)
capable of 175°C continuous operation; and an
ultrasonic welding of copper terminal technology capable of small footprint.
The development of these technologies has
enabled the 2nd generation IPM to reduce its
volume by 30 % and mass by 60 % compared
with the 1 st generation model.
ZERO Heating Power Vending Machine
Energy-efficiency is increasingly being requested for vending machines. Inspired by the
goal of significantly reducing the power consumed in actual operation over the course of a
year, Fuji Electric has developed a vending machine for which a high-thermal efficiency heat
pump can be used all operating conditions,
without employing the electric heaters that had
been used selectively in the past. An approximate 15% reduction in annual power consumption can be achieved in comparison to a conventional energy-saving vending machine.
The main features are as follows:
(1) Only heat pump heating is used inside all
warehouses and in all operating conditions,
and the heating efficiency in the major operating conditions has been improved by
about 50 % compared to conventional models.
(2) The vending machine is equipped with a
high-efficiency compressor, developed in collaboration with a compressor manufacturer,
and modified for vending machine use.
(3) A new of heat exchanger that uses highdensity aluminum fins realizes high heat
exchange efficiency.
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FUJI ELECTRIC REVIEW vol.61 no.2 2015
Donut Fixture for Seven-Eleven Japan
Co., Ltd.
As a follow-up to the “Seven Café” which
was introduced to Seven-Eleven Japan Co.,
Ltd. in 2013, Fuji Electric has developed a
fi xture for selling “Seven Café donuts.” While
maintaining the interior of the showcase at a
constant cool temperature, the cooling method
utilized by this product prevents donuts from
drying out, and is a capable of maintaining the
good taste of donuts.
The main features are as follows:
(1) Using a Peltier cooling unit as the cooler,
precise cold storage performance was realized with an internal cool air circulation
system.
(2) Fuji Electric has developed an exterior that
exhibits a sense of unity with “Seven Café”
and also LED lighting tailored to round
shape design that expresses ease and convenience.
(3) In consideration of the ease of cleanup, an
open and closing front glass structure and a
detachable shelf plate structure were used.
In addition, a sliding shelf system was used
so that the donuts could be removed with
greater ease.
Equipment for Greenhouse
Horticulture of Tomatoh Farm Co., Ltd.
To the Tomatoh Farm Co.’s greenhouse
horticulture, which was built in Tomakomai,
Hokkaido, Fuji Electric has delivered a composite climate control system, substation equipment, environmental measurement equipment,
refrigeration equipment, the next-generation
cold storage container “D-BOX,” and the like.
The composite climate control system, which
is of key importance to the plant, performs
the centralized control of such information as
temperature, humidity, and CO2 concentration,
and also performs high-level climate control
that incorporates time periods and composite
climate data. With this system, the full-year
cultivation of stable and high-quality strawberries is targeted. In addition, because of the heat
supplied from an energy supply center that utilizes wood biomass, a reduction in fossil fuel
usage for facility operation is realized.
In the future, in addition to supplying various equipment and systems, Fuji Electric also
intends to provide comprehensive engineering
for greenhouse horticulture, including administrative and facilities operation know-how to
the operators of greenhouse horticulture.
FUJI ELECTRIC REVIEW vol.61 no.2 2015
101
Arc Coupled Analysis Technology Anticipating
Short-Circuit Faults Inside Switchgear
Pressure rise (a.u.)
1.0
Measured result
0.8
Calculated result
0.6
0.4
0.2
0
0
0.02
0.04
0.06
Time (s)
0.08
0.1
(a) Comparison of pressure rise inside the switchgear
(b) Internal arc test for the switchgear (third-party certification testing)
102
International standard (IEC 62271-200)
stipulate safety performance regarding shortcircuit faults that occur inside switchgears.
The standard requires a structure that can
correspond to arc related pressure rise at the
time of a fault.
To comply with these standards, Fuji
Electric has developed analysis tools for implementing thermo-fluid analysis utilizing a
three-dimensional simple finite volume method specialized for switchgears, as well as arc
coupled analysis for anticipating the arc energy
to be generated. As a result, the following has
become possible:
(1) Consideration of shape and pressure discharge structure for the switchgear
(2) Significant reduction in analysis time
(about 1/100th of conventional methods)
(3) High-precision prediction of pressure rise
inside the switchgear (see Fig. (a))
(4) Design capable of meeting safety requirements for inside and outside the switchgear
through the use of high-temperature gas
convection analysis and strength analysis
The analysis tools were used to create a
switchgear design that passed a third-party
certification test (see Fig. (b)), and as a result,
we have developed and are supplying the market with IEC standard compliant switchgear.
FUJI ELECTRIC REVIEW vol.61 no.2 2015
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